Management scheme for multiple battery cells

ABSTRACT

A series-parallel battery system with a buffer resistor coupled to each junction of batteries or battery cells. Buffer resistors on the same row are coupled to a measurement node. Terminals of the battery system and the measurement nodes are treated as measurement points that are coupled to a conventional battery management unit. The buffer resistors provide a means for limiting in-rush current and a means for maintaining voltage balance across the row of batteries in the parallel columns of batteries. A control unit in series with each series of batteries monitors current in the series and comprises a switch to deactivate the column when the current exceeds a set of predetermined current levels.

BACKGROUND OF THE INVENTION

1. Field of Invention

This invention relates to batteries, in particular to large capacitysecondary batteries comprising multiple cells.

2. Description of Related Art

A secondary battery is a rechargeable battery, whereas a primary batteryis a battery that cannot be recharged. A lithium-ion secondary batteryexhibits high voltage, high capacity, and low self-discharge, and ispopular source of portable electrical energy. However compared withother types of secondary batteries, a lithium-ion battery poses greatersafety hazard. Therefore constant monitoring and control of its current,voltage, temperature, and some other parameters under a batterymanagement unit (BMU) are often required.

A cell is a basic electrochemical unit capable of storing electricalenergy, but not necessarily resilient against handling and environmentalstresses. A battery comprises at least one cell, and is physicallyresilient enough to survive reasonable handling. There is a significantoverlap between these two definitions. In literature and in thisdisclosure, the word “battery” and the word “cell” are often usedinterchangeably.

Large capacity batteries in general comprise multiple cells connected inparallel to deliver the required current and in series to deliver therequired voltage. In the simplest configuration, a plurality of cellsare connected in series such as can be found in a typical flashlight. Ifmore current is required at a particular voltage, an additional seriesof cells are connected in parallel to a first set of series connectedcells.

Shown in FIG. 1A is a series-parallel connected battery scheme of priorart, where several columns 11 of series connected cells 10 are connectedin parallel between a plus voltage output terminal 12 and a minusvoltage output terminal 13. The number of cells in a column establishesthe required voltage and the number of columns connected in parallelprovide the required current. The series-parallel configuration ensuresthat current except for leakage current is identical throughout eachcolumn. Therefore, current distribution within the battery can bemonitored and manipulated per column, and not per cell. When a shortcircuit develops in any column, inrush of current from other columns islimited by the internal resistance of all cells not containing theshort. However in this configuration, the voltage of each cell needs tobe monitored and balanced separately.

An alternative parallel-series scheme of prior art is shown in FIG. 1B,where a number of cells 10 are connected in parallel to form a row 15,and to provide the required current. Then a number of rows 15 areconnected in series to provide the required voltage between the plusvoltage output terminal and the minus output voltage terminal. In aparallel-series matrix of lithium-ion rechargeable cells, the voltage ofeach row needs to be monitored and balanced separately. Uniform currentis not insured among parallel cells in any row 15, wherein, forinstance, cell impedance can vary with local temperature. When ashort-circuit develops in one of the cells, inrush of current fromparallel cells is limited only by internal resistance of cells in asingle row. Thus the inrush current is greater than that with aseries-parallel configuration shown in FIG. 1A.

By elementary physics, current is inherently identical throughout eachisolated series, while voltage is inherently identical across eachparallel connected row. A series-parallel configuration and aparallel-series configuration each takes advantage of one of the abovetwo laws of physics, to simplify current and voltage control,respectively. However neither configuration is able to simplify bothcurrent and voltage controls. A series-parallel configuration requiresvoltage control for each cell, while a parallel-series configurationsuffers from the lack of current control for each cell. In a thirdconfiguration (not shown) voltage and current of each cell in a matrixof batteries are independently monitored and controlled providing acomplex scheme. In addition more energy is dissipated as a result of thenumber of controllers that are needed.

U.S. Pat. No. 7,459,882 B2 (Morgan) is directed to an improvedrechargeable battery, which comprises a plurality of battery cellsconnected together to discharge in parallel each of the cells, or eachgroup, or groups of cells that have their own respective recharginginput as well as a switching circuit to connect the cells or groups ofcells to a charging input. In U.S. Pat. No. 7,394,225 B2 (Guang et al.)a multiple cell battery charger is directed to being configured in aparallel configuration to provide constant current charging. U.S. Pat.No. 7,276,881 B2 (Okumura et al.) is directed to a method of protectionfor preventing battery cells from over discharge and over charge. U.S.Pat. No. 6,777,908 B2 (Thorne et Al.) is directed to a battery cellbalancing method and apparatus to balance cells within a battery whereat some of the cells are arranged in series or a combination of seriesand parallel. U.S. Pat. No. 6,735,098 B2 (Hussein et al.) is directed toan inrush current limiting circuit, a power source device and a powerconversion device. U.S. Pat. No. 6,417,646 B1 (Huykoman et al.) isdirected to a circuit to protect individual cells of a multi-cellbattery from overcharge and to collect data to determine of the cellstate of health. In U.S. Pat. No. 6,160,375 (Horie et al.) a seriesarrangement of a plurality of lithium ion cells is directed to uniformcell charge, wherein a Zener diode and a resistor are connected inseries between the positive and negative terminal of each cell to makeuniform cell charge when a positive electrode crystal phase begins. U.S.Pat. No. 6,150,795 (Kutkut et al.) is directed to a battery chargeequalization that is performed by modules in a staggered means betweenpairs of batteries in a series connected string of batteries. U.S. Pat.No. 6,114,835 (Price) is directed to a charge balancing circuit, whichdetermines when to initiate a charge balance mode to equalize charge inat least two cells of a multi-cell battery.

U.S. Pat. No. 6,043,628 (Perelle et al.) is directed to a method andcontrol for cells connected in series, wherein each cell is associatedwith a bypass that is activated by the controls and resulting frommeasurements in order to balance charge and discharge. In U.S. Pat. No.5,956,241 (LaCascio) a battery power circuit comprising a cellequalization circuit is directed to insuring each cell in a multiplebattery cell stack is depleted of charge at an equal rate. U.S. Pat. No.5,821,733 (Turnbull) is directed to a system of charging for a multipleseries connected battery cells and includes a plurality of shuntregulators. U.S. Pat. No. 5,773,159 (Beard) is directed to a batterypack comprising multiple lithium cells connected in series where avoltage miss match between the lithium cells utilizing circuitrycontained within the battery pack. U.S. Pat. No. 5,666,040 (Bourbeau) isdirected to a battery monitor and control system where electronicmodules are connected to terminals of batteries connected in series tocontrol over-voltage, under-voltage, over-temperature and float-voltage.U.S. Pat. No. 5,650,240 (Rogers) is directed to a multi-cell batterysystem for a battery of at least two cells, wherein a selective bypasscan be selected for each of the cells of the multi-cell battery. U.S.Pat. No. 5,578,914 (Morita) is directed to a battery charging system,which is arranged to reduce a bypass capacity to enable a high currentcharging operation. U.S. Pat. No. 5,206,578 (Nor) is directed to amonitoring circuit for batteries while being charged, wherein thebatteries comprise a series connection of cells to prevent damage to thecells. In U.S. Pat. No. 4,061,955 (Thomas et al.) a multi-cell batterysystem is disclosed where each cell has an individual protective circuitand wherein each cell is monitored for over charge and undercharge and abypass circuit is used to remove a bad cell from the series connectionof cells. U.S. Pat. No. 3,872,457 (Ray et al.) is directed to aself-monitoring system for batteries, which scans individual batterycells to detect faulty cells.

There exists a need, addressed by this invention, for a batteryconnection scheme that simplifies the monitor and control of bothcurrent and voltage. More specifically a novel scheme that ensurescurrent uniformity, reduces inrush current, simplifies battery cellbalancing and facilitates short detection is desired.

SUMMARY OF THE INVENTION

It is an objective of the present invention to provide a matrix ofseries-parallel connected battery cells with a spontaneous intra-rowvoltage balancing mechanism, so that inter-row voltage does not need tobe monitored and controlled separately in each series.

It is another objective of the present invention to provide a matrix ofparallel-series connected battery cells with adequate intra-rowisolation, so that current is approximately identical throughout eachseries, that current distribution can be monitored and controlledbetween series, that each cell can be monitored separately for signs ofpending failure, and that inrush current is reduced when a cellexperiences an internal short.

The above objectives are achieved by a novel “hard-series soft-parallel”connection scheme, wherein a hard connection refers to a connection withnegligible resistance, and a soft connection refers to a connection withappreciable resistance, following a convention used in the field ofelectrostatic discharge (EDS) control. The novel configuration combinesfeatures and advantages of series-parallel and parallel-seriesconfigurations. It degenerates to a series-parallel configuration if thebuffer resistors have infinite resistance. It degenerates to aparallel-series configuration if the buffer resistors have zeroresistance.

In a first embodiment of the present invention one or more seriesconnected batteries are connected in parallel between the minus andpositive terminals of the battery system forming a series-parallelbattery configuration. Each series of batteries have the same number ofbatteries, or battery cells, connected between the minus and positiveterminals of the battery system, where the minus terminal of a firstbattery in each series is connected to the minus terminal of the batterysystem. The minus terminal of a second battery in each series ofbatteries is connected to the positive terminal of the first battery.The negative terminal of a third battery of each series is connected tothe positive terminal of the second battery in each series, andcontinuing on until the negative terminal of the nth battery isconnected to the positive terminal of the n−1 battery. The negativeterminal of the first battery in the series connection of batteries isconnected to the negative terminal of the battery system, which in turnis connected to the battery management unit (BMU). The positive terminalof the nth battery of the series connection of n batteries is connectedto the positive terminal of the battery system, which in turn isconnected to the BMU.

A resister, herein noted as a buffer resistor, is connected from thepositive terminal of the first battery in each of the parallel series toa first measurement node 27 (FIG. 2) for the first batteries in theseries of batteries connected in parallel. A buffer resistor isconnected between to the positive terminal of the second battery in eachof the parallel series of batteries to a second measurement node 27 forthe second batteries in series of the batteries connected in parallel. Abuffer resistor is connected between the positive terminal of the thirdbattery in each series of batteries to a third measurement node 27 andcontinues to the nth battery where the positive terminal of the nthbattery in each series is connected directly together forming a positiveterminal of the battery system. Each of the buffer resistors is of aresistive value that is large enough to limit in-rush current when acell develops a serious internal short, and large enough to limitinter-column current during normal operations. Therefore, the value ofthe buffer resistance is considerable higher than the internalresistance of the batteries to which the buffer resistors are connected.At the same time the buffer resistor value needs to be small enough tomaintain voltage balance across the row of batteries in the parallelcolumns of batteries to which the buffer resistors are connected. Theresistance values for the buffer resistors can be met if the resistanceis less than the acceptable voltage deviation divided by the acceptablecontinuous balancing current. For example, if the operating current of alithium battery is approximately 1 A, the acceptable continuousbalancing current is less than 1 mA, and if a voltage imbalance of 10 mVis allowed, then the resistance of the buffer resistors can be in theorder of 10 mV/1 mA=10 Ohms, which is much larger than the internalresistance of the batteries, which is in the order of 0.1 Ohms. When aninternal battery short occurs, the inrush current can be moreeffectively limited by a resistance in the order of 10 Ohms than theinternal resistance of the batteries, which is in the order of 0.1 Ohms.

The first, second and n-1 measurement nodes 27, the negative batterypack terminal 24, and the positive battery pack terminal 25, are coupledto a battery management unit (BMU) through a multiplexer, so that thebattery voltage of can be measured one row at a time. When all batteriesacross the row are at the same voltage, no current flows through thebuffer resistors and the voltage measurement node 27 is exact for allcells in the row. When battery voltages differ across the row, a currentwill flow through the buffer resistors and the voltage at themeasurement node will be the average voltage across the row. Thisconfiguration is symmetrical in the sense that the each series isconnected to the measurement nodes through the same resistance value.There are no distinct “primary” and “auxiliary” series. When a seriousproblem happens, comprising a short or a marked increase in internalresistance of a battery, the voltage of the measurement node will changemarkedly from the expected value and the BMU will measure an out ofbalance of the battery system In another embodiment of the presentinvention, one of the series 38 (FIG. 3) is selected as a “primary”series. All other series 39 are therefore “auxiliary” series. Batteryterminals of the series are connected directly to the measurement nodes;battery terminals of auxiliary series are connected to the measurementnodes through butter resistors. Compared with the first embodiment, n−1buffer resisters are saved, at the expense of symmetry. The primaryseries is balanced directly by the BMU. The other series is balancedindirectly, through the buffer resistors, by the primary series.

In another embodiment of the present invention, each series of batterieshas connected in series with the batteries, a current control element 50(FIG. 6) comprising one or more of the following components: a currentsensing element, and a current control element. The current sensingelement may be a resistor, a Hall sensor, or a magneto-resistive sensor.The current control component may include one or more of the followingparts: an adjustable resistor for balancing the current distributionduring assembly or scheduled maintenance, an electronic switch (e.g. aCMOS gate) in parallel with a low resistance resistor. for in-situcontrol of current distribution between columns, and a switch fordisconnecting the series when a problem is detected.

BRIEF DESCRIPTION OF THE DRAWINGS

This invention will be described with reference to the accompanyingdrawings, wherein:

FIG. 1A is a schematic diagram of prior art for a series-parallelconnection of batteries;

FIG. 1B is a schematic diagram of prior art for a parallel-seriesconnection of batteries;

FIG. 2A is a schematic diagram of the present invention for asymmetrical hard-series, soft-parallel hybrid connection of batterieswith measurement nodes shared by multiple columns of series ofbatteries;

FIG. 2B is a graph of the present invention showing the relationshipbetween open-circuit voltage and state of charge of a battery;

FIG. 3 is a schematic diagram of the present invention for anasymmetrical hard-series, soft-parallel hybrid connection of batterieswith measurement nodes connected directly to a primary series ofbatteries;

FIG. 4A is a schematic diagram of the present invention of a batterymanagement unit (BMU) coupled to the measurement nodes of a symmetricalhard-series soft-parallel connected battery system;

FIG. 4B is a schematic diagram of the present invention of a batterymanagement unit (BMU) coupled to the measurement nodes of anasymmetrical hard-series soft-parallel connected battery system;

FIG. 5A is a schematic diagram of a novel symmetrical hard-seriessoft-parallel connected battery system in which voltage of each cell ismonitored in addition to the voltage of measurement nodes;

FIG. 5B is a schematic diagram of a novel asymmetrical hard-seriessoft-parallel connected battery system in which voltage of each cell ismonitored by the BMU;

FIG. 6 is a schematic diagram of the present invention where a currentcontrol unit is connected in each series of the series-parallel batterysystem.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

A series-parallel connection scheme in the prior art is characterized byelectrical isolation between parallel-connected series, whereas aparallel-series connection scheme in the prior art is characterized bylow-resistance electrical connection between parallel connected series.The conditions of “adequate electrical isolation” and “adequateelectrical conduction” are not mutually exclusive, because events thatcall for electrical isolation and events that call for electricalconnection exhibit drastically different time constants. Specifically,electrical isolation between columns is desirable during normal chargingand discharging, which last hours or minutes. Electrical isolationbetween columns is also desirable when a cell develops internal short.In this case the damaging inrush current lasts minutes or seconds. Incontrast, electrical connection across the row is desirable only for thepurpose of voltage balancing, the time constant of which is in the orderof months or years. A connection across each row can be made with anintermediate time constant, for example a few days, so that adequateisolation and adequate conduction are both achieved. This novelconfiguration can be characterized as a “hard-series, soft-parallel”configuration, wherein a hard connection refers to a connection withnegligible resistance, and a soft connection refers to a connection withappreciable resistance. Since the novel configuration combines desirablecharacteristics of series-parallel and parallel-series configurations,it may be called a “hybrid” configuration.

Shown in FIG. 2A is a first embodiment of the present invention, whichrepresents a symmetrical hard-series, soft-parallel arrangement 20 ofbatteries, or battery cells 21. The batteries 21 are connected in acolumn of series connected batteries 22 between the minus 24 andpositive 25 terminals of the battery system, and then a number of thesecolumns of series connected batteries are connected in parallel formingrows 23 of batteries across the columns. It should be noted thatalthough FIG. 2 shows three columns 22 of four serial connectedbatteries 21, a more general configuration is m columns of n serialconnected batteries that is within the scope of the present invention.

Connected to each positive terminal of each battery 21 is a resistor 26,except at the positive end of each series, which connects to thepositive terminal 25 of the battery system. The resistors 26 of each rowof batteries 23 are further connected to a measurement node 27. In FIG.2 where n=4 there are n−1=3 measurement nodes. Each measurement node 27,together with the positive terminal 25 and negative terminal 24 arecoupled to a BMU, which monitors and balances voltage between successivenodes or terminals, i.e., the voltage of each row 23. It is known in theprior art that a BMU typically contains a multiplexer (not shown), whichallows a plurality of rows to be monitored successively, using a singleanalog to digital (A/D) converter. The BMU may also establish a shuntpath to drain rows of excess charge, or transfer the excess charge torows, which are deficient in charge. The resistors 26 have a resistancevalue that is higher than the internal resistance of each individualbattery 21 to which the resistors are connected, where the internalresistance of the batteries is typically in the order of 0.1 Ohms. Theresistors 26 need to be high enough in resistance to limit in-rushcurrent when a battery shorts, and to limit inter-column current so thatthe normal operating current is substantially identical throughout thecolumn. Resistance of resistor 26 also needs to be small enough in valueto allow inter-column current to maintain voltage balance across a rowof batteries 23.

The intra-column operating current of lithium-ion battery 21 istypically in the order of 1 Ampere, whereas an inter-column balancingcurrent of less that 1 mA is all that is required to keep a battery 21balanced with respect to other batteries 21 in the same row of batteries23. Thus if a balance voltage of 10 mV is allowed, then the value of theresistor 26 can be allowed to be approximately 10 Ohms. This upper boundof 10 Ohms is much greater than the lower bound of 0.1 Ohm, which is theinternal resistance of the batteries 21. An intermediate value of 1 Ohmwill provide adequate barrier for inrush current, keep intra-columncurrent substantially identical, and keep intra-column battery voltagesbalanced with ample margin.

It should be noted that the tolerance in voltage balance depends on thestate of charge and the chemistry of the battery cell design. The stateof charge is the ratio of available charge over the capacity of thebattery. A lithium-ion battery typically exhibits a “plateau” in whichthe battery voltage is a weak function of its state of charge as shownin FIG. 2B. The maximum acceptable resistance of resistor 26 is denotedas Rmax and calculated by Rmax=(ΔSOC×[k])/i, where ΔSOC is the tolerancein state of charge, i is the range of battery 21 self-discharge current,[k] is a weighted average of the slope in FIG. 2B and where theweighting factor is the expected time a battery 21 will spend on thecorresponding state of charge.

It should also be noted that intra-column current required for voltagebalancing is small, because intra-column balancing is spontaneous andcontinuous. In contrast, inter-row voltage balancing is controlled bythe BMU, usually with a very low duty cycle. Specifically, mostoff-the-shell BMU performs inter-row voltage balance only duringcharging, and only when the charging is almost completed. Therefore aBMU designer may be accustom to a much larger balancing currentrequirement that what is needed in the novel soft-parallel connections.

The resistance of buffer resistors 26 can be optimized by an alternateapproach, which focuses on the time-constant of intra-row current. It isunderstood by those skilled in the art that a battery cell exhibits acapacitance, which varies with its state of charge. The product ofcapacitance and resistance defines a time-constant of a cell with itsbuffer resistors, which should be much greater than the time-constant ofinrush current in a conventional parallel-series configuration that istypically a few minutes, and much smaller than the time-constant ofacceptable self-discharge that is typically a few months. Therefore, theacceptable range of resistance for buffer resistors 26 is very wide.

Design of buffer resistor 26 based on time-constant, rather thancurrent, is especially convenient in the case columns 22 are notidentical. For example, a battery system may be physically distributedin different locations, some of which have more space available thanothers. A battery system may also comprise of one or more columns ofenergy cells in parallel with one or more columns of power cells.Furthermore, one or more columns of cells may be added to an existingbattery pack. In these cases, buffer resistors connected to each battery21 should be designed such that each battery 21 together with its bufferresistor(s) 26 exhibit substantially the same time-constant.

Buffer resistors limit the dissipative balancing current of battery 21to which they are connected. Specifically when a BMU shunts a row ofbatteries to drain excess charge, the discharge current must flowthrough buffer resistors 26. Ideally, the resistance of buffer resistors26 should be selected such that no additional current limiter isnecessary to further reduce the speed of inter-row voltage balancing.The first embodiment is symmetric in the sense that each column exhibitssubstantially the same time-constant, with respect to the pack terminals24, 25 and measurement nodes 27. It should be noted, however,time-constant of batteries on the top and bottom rows, i.e., batteriesdirectly connected to the pack terminals 24 or 25, is approximately halfof time-constant of all other cells. This difference is due to the factthat both ends of each series must be connected directly to minimizetransmission loss in the electrical power. Fortunately, the designmargin of buffer resistors is much wider than the fact of two. Thereforethe absence of buffer resistors in both ends of the battery pack doesnot seriously impair intra-column isolation in the top and bottom rows.

Shown in FIG. 3 is a second embodiment of the present invention whereone of the columns is connected directly to measurement nodes 27,without buffer resistors 26. This column is called a “primary series”38. All other columns are coupled to measurement nodes 27 through bufferresistors 26, as in the first embodiment. Columns other than the primaryseries are called “auxiliary series” 39. Voltage of batteries 21 in theprimary series are monitored and balanced directly through measurementnodes 27, whereas batteries 21 in auxiliary series are not monitored.Inter-row voltage balance in auxiliary series is achieved indirectly, bythe primary series through buffer resistors 26.

Compared with the first embodiment, the second embodiment requires n-1fewer buffer resistors 26. Often, this saving alone does not justify itsloss of symmetry, because asymmetry complicates control, especially ininter-row voltage balancing. The second embodiment is preferred over thefirst embodiment when the inter-row voltage balancing involves a largecharging current, which occurs when the balancing is accomplished bycharge transfer rather than by dissipation, and when the balancingexhibits a very low duty cycle. In this case, the inter-row balancingcharge can be transferred to a battery 21 in the primary series 38quickly, and then spread to battery 21 in auxiliary series gradually tominimize heat dissipation. The second embodiment may also be preferredwhen an existing battery pack is expanded by appending an extra columnof cells, because this embodiment requires less modification to thepack.

In FIG. 4A is shown an example of the first embodiment of the presentinvention coupled to a BMU 42. The BMU is connected to measurement nodes27, which are formed by the connecting together of the buffer resistors26 that are connected to the positive battery terminals of each of the nto n−1 rows of batteries. The negative terminals of the n=1 row ofbatteries are connected together to form the negative terminal of thebattery system and connected to the BMU 42. The positive terminals ofthe nth row of batteries are connected together to form the positiveterminal of the battery system and connected to the BMU 42.

In FIG. 4B is shown an example of the second embodiment of the presentinvention coupled to a BMU, where the second column (m=2) is shown to bethe primarily series. However the physical location of primary series isarbitrary. In both FIG. 4A and FIG. 4B, a hard-series, soft-parallelarrangement of batteries 21, or battery cells, is shown with n=4batteries hard-connected in series, and m=3 columns soft-connected inparallel.

BMU pins and connections unaffected by this invention, for exampleconnection to the temperature sensor(s), to the current sensor, and tothe charge/discharge switches, are omitted for clarity. It should benoted that the BMU connection in both FIG. 4A and FIG. 4B are identicalto that of a conventional parallel-series configuration. In the firstembodiment, the voltage monitor and balancing algorithm, includingparameter setting, can be identical to that of a conventionalparallel-series configuration. In the second embodiment, the voltagebalancing algorithm and parameter setting, may differ slightly from thatwith a conventional parallel-series configuration, to account for thegradual equalization between primary and auxiliary series. In general, aconventional parallel-series configuration can be upgraded to the novelhard-series, soft-parallel configuration without minimal effort.

In the first two embodiments described above, soft-parallel connectedcells are not monitored individually. Signs of pending failure of singlecell, for example an increase in self-discharge current, and a change indirect current resistance (DCR) or impedance, are difficult to detectbecause measurements are made at nodes 27 and not directly on theterminal of the cells. In FIG. 5A is shown a third embodiment of thepresent invention, where terminals 51 in the first embodiment areconnected to the BMU so that individual cell voltages can be measured.Similarly in FIG. 5B is shown a fourth embodiment of the presentinvention, where terminals 51 in the second embodiment are connected tothe BMU so that individual cell voltages can be measured.

In both FIG. 5A and FIG. 5B, terminals 51 are connected directly to theBMU. It shall be understood by those skilled in the art that thesevoltages can be measured either simultaneously in parallel, orsequentially by multiplexing, which may be performed either outside orinside of the BMU. It should also be understood by those skilled in theart that instead of, or in addition to, the cell voltages, intra-rowcurrent to or from an individual cell may be monitored by acurrent-sensor, which may be either a small resistor inserted betweenterminals 51 and BMU 42, or a remote sensor positioned adjacent to theelectrical lead between terminal 51s and BMU 42.

It should also be noted that figures and discussions herein are anexample of a battery system and corresponding battery management system.The number of batteries n in series and the number of columns ofbatteries m in parallel are not limited to the example of any of thefigures shown herein.

A major advantage of the present invention over a conventionalparallel-series connection scheme is that in each of the fourembodiments, current distribution among hard-series can be adjustedduring assembly, or controlled during application. In FIG. 6 is shown aschematic diagram of the fifth embodiment of the present invention,wherein a control unit 50 is inserted in each column of cells in thefirst embodiment. Although control units 50, as shown, are connectedbetween the negative terminal 43 and the n=1 row of cells, it should benoted that a control unit 50 can be inserted anywhere in the series. Itshould also be noted that control units 50 can be similarly inserted inthe second, third, and fourth embodiments. The control unit 50 is inessence a variable resistor, which may be adjusted manually duringassembly and maintenance, or controlled automatically duringapplication. A control unit 50 comprises of one or more of the followingelements: i) a switch, relay, or contact, which is inexpensive, yetuseful in diagnostics, and allows a battery pack to work at reducedcapacity, in case one series fails; ii) a fuse that can be activated byeither temperature or current, where the fuse may or may not be able tobe reset. A fuse protects a series from overload, or operating atexcessively high temperature; iii) a positive thermal coefficient (PTC)device in which resistance increases monotonically, reversibly, andnonlinearly with temperature. A PTC may offset the negative thermalcoefficient of cell internal resistance, thus reducing the sensitivityof current distribution to thermal gradient within the battery pack. APTC also functions as a thermal fuse that can be rest; iv) alow-resistance adjustable resistor, for example a strip of conductorwhose resistance may be decreased by adding a conductor in parallel(e.g., adding solder on the surface of strip, or soldering additionalconductor to the strip), and increased by blocking the conductive path(e.g., punching a hole on the strip, or cutting off a portion of thestrip). It is useful during assembly and maintenance; v) a currentsensor; and vi) an electronic switch (e.g. a CMOS device), which may beused to control current distribution by feedback control. The design andconstruction of control unit 50 are quite flexible to those skilled inthe art.

Control units 50 must be extremely reliable. A single failure may open aseries and divert its share of current onto other series, thusoverloading them. Control units 50 must also exhibit low power loss andheat generation. Efforts should be made to reduce or eliminate the needfor unreliable or heat generating components. Before assembly, cells 21should be selected and grouped such that capacity C is approximatelyidentical among all cells 21 in the same series 22. In the design, theRC product of internal resistance R and capacity C of all series 22 mustbe identical in the entire matrix. The equality of RC must be verifiedduring assembly and maintenance. Note that internal resistance R varieswith temperature, and that temperature within the battery pack is notuniform. The battery and its thermal control system should be designedsuch that the average temperature of each series remains equal. Thiswill minimize the effect of pack temperature variation on currentdistribution.

While the invention has been particularly shown and described withreference to preferred embodiments thereof, it will be understood bythose skilled in the art that various changes in form and details may bemade without departing from the spirit and scope of the invention.

What is claimed is:
 1. A battery management system, comprising: a) aseries-parallel battery system further comprising m columns, whereineach column comprises n batteries connected in series between negativeand positive terminals of the battery system, and wherein m and n areintegers greater than one; b) a positive battery terminal of eachbattery in a top row of batteries in the m columns coupled to a positiveterminal of the battery system and a negative battery terminal of eachbattery in a row of bottom batteries in the m columns coupled to a minusterminal of the battery system; c) a single row of positive batteryterminals formed from a single row of batteries located below said toprow of batteries, wherein each positive battery terminal of said singlerow of positive battery terminals connected by a buffer resistor to asingle measurement node of a battery management unit (BMU) located insaid single row of positive battery terminals, wherein a value of saidbuffer resistor is small enough to maintain a voltage balance acrosssaid row of battery terminals and large enough in resistance value tolimit in-rush current when a short develops; and d) said measurementnodes connect to said battery management unit (BMU) to provide ameasurement of battery system performance and detect a failure of saidbattery system.
 2. The system of claim 1, wherein said series-parallelbattery system further comprises a control unit in each column of the mcolumns to adjust current distribution among the m columns.
 3. Thesystem of claim 2, wherein said control unit further comprises a currentsensor to monitor current and a switch controlled by the batterymanagement unit (BMU) to turn off a failing column of the m columns ofbatteries.
 4. The system of claim 3, wherein said BMU monitors voltageof each battery in the battery system.
 5. The system of claim 1, whereinsaid buffer resistors are connected between each positive batteryterminal in a row of positive battery terminals and the measurement nodeexcept for one battery terminal, which is coupled directly to themeasurement node.
 6. The system of claim 1, wherein said batteries areselected and grouped such that batteries in the same column are ofapproximately the same capacity, and a product of capacity and internalresistance of the batteries are approximately identical among columns inthe battery system.
 7. The system of claim 1, wherein said batterysystem further comprises packaging and cooling arranged such that anaverage temperature of batteries in each column is approximatelyidentical.
 8. The system of claim 1, wherein said buffer resistors arelarger in resistance value than an internal resistance of the batteriesto which the buffer resistors are connected.